Corrugated box

ABSTRACT

A corrugated box may include a plurality of sidewall portions separated by a fold line and a plurality of flaps extending from the sidewall portions and isolated from one another by a slot arranged in alignment with the fold line when the flaps are unfolded and the slot may include a fold line end comprising a stress relieving termination and a handle may be provided that may include a cutout line with a return portion foaming a stress relieving end and a series of tabs may be provided for securing a seam of the box.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application No 61/758,430, filed on Jan. 30, 2013, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present application relates to containers for storing and transporting materials. More particularly, the present application relates to containers adapted for handling by human hands or automated systems and for storing and transporting goods. Still more particularly, the present application relates to foldable corrugated box type containers with or without handles and/or a unique corner design and/or seam design.

BACKGROUND

Corrugated material, including cardboard, plastic, or other materials, may generally include an outer surface material and an inner surface material that are separated from one another and connected by a series of flutes extending generally in one direction. Such a fluted structure may provide durable walls for containers such as boxes. In some cases, however, the fluted nature of the corrugated material can lead to deterioration particularly along the length of the flutes. For example, where a tear or crack begins on an edge or near a corner of a piece of corrugated material, the crack may have a tendency to propagate relatively quickly in the direction of the flutes since there is generally an absence of crossing elements that may arrest such propagation. It is not uncommon for such tears or cracks to originate at the corners of boxes and at the handles of boxes.

Boxes are often assembled by folding a flat piece of corrugated material to form sidewalls and a bottom of a box and, often times, a top of a box. The starting flat piece of material may have flap portions extending from the sidewall portions, for example, such that once the sidewalls of the box are formed, the flap portions may be folded to form the bottom or top of the box. In the flat condition, these flap portions may be separated by a slit or slot in the flat piece of material and the slit or slot may sometimes be aligned with a fold line between two sidewalls, for example. In some cases, the base of the slit or slot may form the originating location for a tear or crack discussed above. Moreover, the location of the end of the slit or slot being adjacent a fold line and at a corner of the box may cause it to see stress concentrations that can encourage propagation of the tear down the fold line between two sidewalls.

Similarly, hand holds may be provided in corrugated containers by providing a cutout line or boundary that defines a punch out where the portion of the box defined by the cutout line may be fully punched out or the portion defined by the cutout line may be partially punched out and folded out of plane of the surrounding material to form an opening. Like the base of the slit or slot described above (i.e., the originating location for a tear or crack), the ends and/or top of the cutout area may be susceptible for tearing or cracking and, in particular, where the punched out area is used for lifting of the container, stress concentrations may be created at the end or top of the punched out area and can lead to propagation of a tear or crack.

Still further, the folded nature of box construction creates a seam where two sides of the folded enclosure come together and are secured. In some cases a single flap may be provided that is glued, welded, or otherwise adhered across the seam. However, similar to the fluted corrugated material where there is an absence of crossing elements or interrupting features, the adhered flap likewise may have nothing to arrest a seam failure if, for example, an end of the seam begins to tear, crack, peel or loosen. As such, a zipper effect may be realized where the seam weakness propagates along the length of the seam and causes the seam to fail. These and other problems may be addressed in the present application.

SUMMARY

In one embodiment, the present application includes a corrugated box including a plurality of sidewall portions separated by a fold line and a plurality of flaps extending from the sidewall portions. The flaps may be isolated from one another by a slot arranged in alignment with the fold line when the flaps are unfolded and the slot may have a fold line end that includes a stress relieving termination.

In another embodiment, a corrugated box with a sidewall may include a handle arranged on the sidewall. The handle may include a cutout line extending through the sidewall and the cutout line may have a substantially straight bottom portion and two substantially curved end portions defining a return along the top of the cutout line.

In still another embodiment, a corrugated box may include a plurality of sidewalls arranged adjacent to each other and defining a seam there between. The sidewalls each may include a seam edge and may have a plurality of tabs extending from the seam edge, the tabs being arranged adjacent an inner or outer edge of the adjacent sidewall and being secured thereto.

While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description. As will be apparent, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the detailed description is to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a box, according to some embodiments.

FIG. 2 is a view of a flat blank for forming the box of FIG. 1.

FIG. 3 is a close-up view of a slot between flaps of the blank of FIG. 2.

FIG. 4 is a close-up view of a handle of the blank of FIG. 2.

FIG. 5 is a close-up view of a reinforced seam of the box of FIG. 1.

DETAILED DESCRIPTION

The present application, in some embodiments, is directed toward a box configured to resist cracking, tearing, or other deterioration during use The box may be particularly adapted to resist deterioration at the corners of the box where fold lines between sidewalls come together and where folding flaps that may form the top or bottom of the box are separated by a slot that terminates at the corner. For example, the slot formed between the flaps may be terminated with a radiused or otherwise curved shape such that stresses from stress concentrations that occur at the corners may be guided or routed through the corner of the box in a manner that resists cracking or tearing of the box. The box may further be particularly adapted to resist deterioration at the handles. For example, the cutout line that defines the handle may extend upwardly along each side of the punched out area and return across the top of the handle in a radius fashion such that stresses from stress concentrations that occur at the handles may be guided or otherwise routed from the handle and into the sidewalls of the box in a manner that resists cracking or tearing of the box. Still further, the box may be particularly adapted to resist rupture along the seam of the box by having a series of interlocking tabs or wrap tabs.

Referring now to FIG. 1, a perspective view of a box 100 is shown. The box 100 may include a plurality of sidewalls including, for example, a front 102, a back 104, a left 106, and a right sidewall 108. The box 100 may also include a bottom wall 110 and a top wall 112. It is noted that the particular names of the respective walls of the box 100 are for purposes of discussion only and other orientations and arrangements including boxes with more or fewer than six walls may also be provided. For example, boxes without tops or boxes with selectively omitted walls, may be provided. As shown in FIG. 1, the box 100 may include a plurality of corners 114 formed by the intersection of three walls and the box 100 may also include edges 116 formed by the intersection of two walls. Still further, the box 100 may also include handles 118 extending through one or more of the sidewalls. It is to be appreciated that some boxes 100 may be provided without handles 118 or with more than two handles 118 as shown. Still other numbers of handles 118 may be provided.

Referring now to FIG. 2, a box blank 120 is shown in a flat configuration. The blank 120 may have a geometry configured for folding to form the box 100 of FIG. 1, for example. The box blank 120 may include sidewall portions as shown including a back sidewall portion 122, a left sidewall portion 124, a front sidewall portion 126 and a right sidewall portion 128. The top and bottom walls 112, 110 of the box 100 may be formable by folding a plurality of flaps. In the flat condition, the flaps may extend from the several sidewall portions of the box blank 120. For example, as shown, the box blank 120 may include a bottom back flap 130, a bottom left flap 132, a bottom front flap 134, and a bottom right flap 136. Each of these bottom flaps may be foldable and compatible to form the bottom 110 of the box 100 and may extend from respective sidewall portions of the box blank 120. It is noted that the particular shape of the flaps 130-136 shown may be provided to create an auto forming bottom of the box, but other flap shapes may be provided such as the more rectangular flaps shown, for example, for the top flaps. Still other flap shapes and sizes may be provided for the bottom of the box 100.

In some embodiments, as is the case with the box 100, a top may be provided. In this embodiment, the box blank 120 may also include a top back flap 138, a top left flap 140, a top front flap 142, and a top right flap 144. As with the bottom flaps, these top flaps may be foldable and compatible to form the top 112 of the box 100 and may extend from respective sidewall portions of the box blank 120. The top flaps may be configured to fully cover the top of the box or the flaps may configured to partially cover the top of the box as shown in FIG. 1.

In the present embodiment, a seam may be formable between a free edge 148 of the back sidewall portion 122 and a free edge 150 of the right sidewall portion 128. Each of the free edges 148, 150 may include one or more tabs for securing the free edges 148, 150 adjacent to one another. For example, as shown, the free edge 148 of the back sidewall portion 122 may include a central tab 152 and an upper and lower tab 154, 156. In some cases, for relatively shallow boxes, for example, the central tab 152 may be omitted. The free edge 150 of the right sidewall portion 128 may include an upper and lower tab 158, 160. The upper and lower tabs 158, 160 of the right sidewall portion 128 may be similar in length and width and location of the upper and lower tabs 154, 156 on the back sidewall portion 122. As the free edges 148, 150 of the back and right sidewall portions 122, 128 are brought together, the tabs may be folded approximately 90 degrees relative to their respective sidewall portions and may lie adjacent an outer or inner surface of the adjacent sidewall portion. Where each free edge 148, 150 has corresponding tabs (e.g., where each edge has an upper tab) the tab from one sidewall portion may lie adjacent an inner surface of the opposing sidewall portion while the tab from the other sidewall portion may lie adjacent an outer surface of its opposing sidewall portion. In some embodiments, one or more tabs from a free edge may lie adjacent an inner surface of the opposing sidewall portion while one or more tabs from the same free edge may lie adjacent an outer surface of the opposing sidewall portion to create an interlocking effect for securing the seam. Further discussion of the use of the tabs to secure the seam is provided with respect to FIG. 5.

The several sidewall portions may be separated by fold lines. The fold lines may include a creased, weakened, perforated, surface marked, scored, or imaginary portion of the blank that identifies an intersection between two or more portions of the blank and further identifies a line along which the blank 120 may be folded to form the box 100. As shown in FIG. 2, the blank 120 may include sidewall fold lines including a back/left fold line 162, a left/front fold line 164, and a front/right fold line 166. Additionally, flap fold lines 168 may also be provided between the sidewall portions and each of their respective top and bottom flaps.

The sidewall fold lines of the blank 120 may be arranged to align with separation areas 170 arranged between the top flaps or bottom flaps of adjacent sidewall portions. For example, as shown, the back/left fold line 162 may be arranged to align with a separation area 170 between the back top flap 138 and the left top flap 140. In this case the separation area 170 may be a slot. The back/left fold line 162 may also be arranged to align with a separation area 170 between the back bottom flap 130 and the left bottom flap 132. In this case, the separation area 170 may be a triangular gap. Other shapes of the separation areas 170 may also be provided.

Referring now to FIG. 3, a close-up view of a separation area 170 or slot is shown and it is located between top flaps of the blank 120 previously shown in FIG. 2. As shown, the slot may be provided between adjacent top flaps of the blank 120 such that the flaps may move independent of one another when the blank 120 is folded to form a box 100. With continued reference to FIG. 3, the slot may be defined by two adjacent parallel flap edges 172, 174. (Note: detailed slot reference numerals omitted from FIGS. 1 and 2 for clarity) The adjacent flap edges 172, 174 may be separated by a slot having a width 176. As shown, the slot may include a stress relieving termination 178 arranged at the intersection between the slot and the end of the respective fold line (i.e., a fold line end) between the respective sidewall portions.

The stress relieving termination 178 may generally include a curved shape leading from one of the flap edges 172 to the other adjacent and opposing flap edge 174. In one embodiment, the generally curved shape may include a dog bone shape. For example, as shown, each of the flap edges 172, 174 may include a first curved portion 180 extending from the flap edge 172, 174 and diverging away from the opposing flap edge 172, 174. In some embodiments, the first curved portion 180 may be a radiused curve. The generally curved shape may further include a second substantially straight portion 182 extending from the first curved portion 180 and leading to a third curved portion 184. The third curved portion 184 may extend from the second substantially straight portion 182 and may converge back toward the opposing flap edge 172, 174 until it is parallel to the opposing flap edge 172, 174. In some embodiments, the third curved portion 184 may include a radiused curve. A fourth substantially straight portion 186 may connect the respective ends of the third curved portion 184 of the opposing flap edges 172, 174 to complete the dog bone shape. Referring back to FIG. 1, the dog bone shaped stress relieving termination 178 is shown with a formed box 100 and is apparent from the rounded openings near the corners 114 of the box 100. As shown, the dog bone shaped termination helps to avoid abrupt ends to portions of the box 100 which may create opportunities for cracks or tears to begin and from which the cracks or tears may propagate.

In still other embodiments, the generally curved shape may have a key hole type shape. For example, where flap edges 172, 174 are approaching a fold line, a curved shape that begins by angularly diverging away from the opposing flap edge 172, 174 may then converge toward the opposing flap edge 172, 174 and may extend beyond the opposing flap edge 172, 174 and curvingly continue back to the opposing flap edge 172, 174. For example, the generally curved shape may be a portion of a circle and the circle may have a diameter larger than the slot width 176 between the two flap edges 172, 174. Variations of this embodiment may include a circle with a diameter equal to the slot width such that the end of the slot includes a radiused end between adjacent flap edges 172, 174. In still other embodiments, an oval shaped end or Q-tip shaped end of the slot may be provided. Still other generally curved shapes may be provided that may assist in suitably relieving stresses at the corners of the formed box 100 providing smooth transitions between the respective portions of the box approaching the corners.

In other embodiments, alternative generally curved shapes may be provided. For example, between the bottom flaps of the blank 120 where the adjacent edges 172, 174 of the flaps might not be parallel, the generally curved shape may include a curve that extends from one end of one of the flap edges 172, 174 and converges toward the opposing flap edge 172, 174 until it is parallel thereto. As such, the generally curved shape may include a smooth curve transition from one flap edge 172, 174 to another 172, 174. It is to be appreciated that some of the bottom flaps (i.e., flaps 132 and 136) may include an additional tab with a diagonally extending fold line. When folded, the additional tab may broaden the separation area 170 between respective flaps and, thus, broaden the angle between the edges approaching the corner of the box. This broadened angle together with a smooth curve connecting the edges at the base of the separation area may create a stress relieving termination for the bottom corners of the box. It is to be appreciated where a more conventional bottom with substantially rectangular flaps is provided, the dog bone shaped or other shaped stress relieving terminations described with respect to the top flaps may be provided for the bottom flaps.

Turning now to FIG. 4, a close-up view of the handle 118 is shown, which is located on one of the left and right sidewall portions 124, 128 previously shown in FIG. 2. As shown, the handle 118 may be defined by a cutout line 188 that extends through the sidewall portion creating a sidewall handle edge 190 and a handle flap 192. It is noted that, in some embodiments, the handle flap 192 may be omitted and the cutout may be more akin to a cutout area instead of a cutout line. In the presently shown embodiment, the handle flap 192 may include a relatively straight bottom portion 194 and two substantially vertical and straight end portions 196. The bottom portion 194 and the end portions 196 may be connected by a radiused corner, for example. While a substantially straight end portion 196 is shown, a curved or radiused end portion 196 may also be provided. The sidewall handle edge 190 may be similarly shaped and offset from the edges of the handle flap 192. The sidewall handle edge 190 may extend generally parallel to the straight bottom portion 194 of the handle flap 192. However, in contrast to the generally vertical and straight end portions 196 of the handle flap 192, the end portions 199 of the sidewall handle edge may be substantially curved. The sidewall handle edge 190 and curved end portions 199 may be separated from the handle flap 192 by a gap 198 equal to the cutout line width and the cutout width may vary in size as shown. The cutout line 188 may terminate at or near the top of the handle flap 192 and inward from each end of the cutout line 188 defining a return portion 200. The handle flap 192 may further include a substantially straight fold line 202 that may be double scored, single scored, or some other configuration. The fold line 202 may extend across the top of the handle 118 from one end of the cutout line 188 to the other end of the cutout line 188. The handle flap 192 may, thus, be foldable into or out of the box 100 about the fold line 202 such that a user may place their fingers through the hole created by the folded flap 192 and lifting pressure may be provided against the fold line 202 and the return portion 200 of the cutout line 188 allowing the box 100 to be lifted.

As shown, the cutout line 188 may include a generally curved and/or radius shape forming the curved end portions 199 as it returns from each end and extends to the fold line 202. The curved and/or radius shape of the cutout line 188 may allow for a gradual transition of force transfer from a user's hand (or automated equipment) to the sidewall of the box. That is, as a user, for example, is holding the box, there may be substantially uniform pressure across the fold line 202. Without more (i.e, if the cutout was more squarely cut and extended directly downward from each end of the fold line) the vertical flutes in the corrugated material near the end of the handle may have a tendency to allow a vertical tear or crack to propagate upwardly at each end of the handle. In contrast to such a design, the curved and/or radius shaped end of the cutout line 188 over the return portion 200 may allow for the force transition to be more gradual and may distribute the upward forces further outward into the sidewall and may avoid the high stress concentration near the ends of the handle 118.

Accordingly, as a user or equipment lifts a box 100 with the handle 118, upward forces on the fold line 202 of the handle flap 192 and along the return portion 200 of the cutout line 188 may be gradually distributed to the sidewall portion and distributed across multiple flutes of the corrugated material. This may help to avoiding cracking or tearing that may otherwise occur at the end of an abruptly ended fold line arranged at the outside edge of the handle. As such, cracking or tearing that may otherwise propagate across the handle area or upward through the top of the sidewall may be reduced or avoided.

Referring now to FIG. 5, yet another feature of the box of FIGS. 1 & 2 is shown. As shown, the tabs previously shown in FIG. 2 that extend from the edges 148, 150 of the back sidewall 122 and the right sidewall 128 may be arranged to interlock the adjacent edges 148, 150 of the respective sidewalls. As shown, the upper and lower tabs 154, 156 of the back sidewall 122 may be arranged adjacent the outer surface of the right sidewall 128 while the center tab 152 of the back sidewall 122 is arranged adjacent the inner surface of the right sidewall. Also, the upper and lower tabs 158, 160 of the right sidewall 128 may be arranged adjacent the inner surface of the back sidewall 122. This series of tabs may be used to secure the free edges of the sidewalls to form a seam. It is to be appreciated that other configurations and arrangements of interlocking tabs may be provided. For example a single upper tab may be provided on one sidewall while a single lower tab may be provided on an adjacent sidewall. The upper tab may be secured to an inner surface of the adjacent sidewall and the lower tab may be secured to the one sidewall. In still other embodiments where, for example, the center tab is omitted, the upper and lower tabs from one sidewall may be arranged along the inner surface of an adjacent sidewall while the upper and lower tabs from the adjacent sidewall are arranged along the outer surface of the one sidewall. However, the upper tab from one sidewall may be arranged along an inner surface of the adjacent sidewall and the lower tab from the same sidewall may be arranged along an outer surface of the adjacent sidewall. Accordingly, the upper and lower tabs from the adjacent sidewall may be arranged along the outer and inner surfaces, respectively, of the one sidewall. This interlocking approach may be advantageous to more securely hold the adjacent sidewalls together. Still other arrangements may be provided.

Each of the tabs may be sonically welded to the respective sidewall to secure the tab in position and maintain the position of the respective sidewalls with one another. In some embodiments, for example, each of the upper tabs 154, 158 and each of the lower tabs 156, 160 may include four sonic welds (i.e., an eight pin weld for the top tabs and an eight pin weld for the bottom tabs) and the center tab 152 may include two or more sonic welds. Other numbers of sonic welds and/or other securing means may be used such as staples, adhesives, or fasteners, for example. Still other securing means may be provided to secure the tabs to the sidewalls and maintain the integrity of the seam. It is also noted that while the current box 100 has been shown to include a single seam, two or more seams may be provided and selected based on the size of the box and other factors.

The several features of the box 100 herein described may be advantageous in strengthening the box during storage and use. For example, the stress relieving terminations between the box flaps may function to distribute the pressure/torque across multiple flutes of the corrugated material. This may be advantageous in avoiding ripping, tearing, or cracking of the flutes at the corners 114 of the box 100 and thereby extending the life cycle of the product. Similarly, the generally curved and/or radiused return portion 200 of the cutout line 188 for the handles 118 may function to distribute the pressure/torque across multiple flutes of the corrugated material and avoid ripping, tearing, or cracking and extending the life cycle of the product. Finally, the wrap tabs helping to secure the seam of the folded box 100 may help to avoid popping of the sonic welds in a zipper-like fashion, which may more likely occur if a single full-height tab were used, for example. Still further, the wrap tabs may reduce the potential for a tear or crack to originate at the top or bottom of the box at the seam locations.

It is to be appreciated that at least three concepts for improving box construction have been disclosed herein relating to stress relieving terminations at corners of a box, stress relieving ends and tops of cutout handles, and a wrap tab connection at the seamed edge of a box. However, it is to be appreciated that any one or several of these concepts may be incorporated and/or omitted from a given box. For example, the stress relieving terminations at the corners of a box may be provided, while the box may have handles omitted or handles without the stress relieving ends described. Still further, for example, the wrap tab connection at the seamed edge may or may not be provide on a given box construction. Still other combinations of features or aspects of the box together with or apart from the concepts disclosed herein may be provided.

Although the invention has been described with reference to various embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. 

1. A corrugated box, comprising: a plurality of sidewall portions separated by a fold line; and a plurality of flaps extending from the sidewall portions and isolated from one another by a slot arranged in alignment with the fold line when the flaps are unfolded, the slot having a fold line end comprising a stress relieving termination.
 2. The box of claim 1, wherein the stress relieving termination comprises a dog-bone shape.
 3. The box of claim 1, wherein the each of the plurality of flaps include flap edges adjacent the slot and each of the edges comprises a first curved portion diverging from the opposing flap edge, a second substantially straight portion extending to a third curved portion converging toward the opposing flap portion.
 4. The box of claim 3, wherein each of the third curved portions converge until they are parallel to one another.
 5. The box of claim 4, wherein the third curved portions are connected by a fourth substantially straight portion.
 6. A corrugated box with a sidewall, the box comprising: a handle arranged on the sidewall, the handle comprising: a cutout line extending through the side wall, the cutout line having a substantially straight bottom portion and two substantially curved end portions defining a return along the top of the cutout line.
 7. The corrugated box of claim 6, wherein the substantially curved end portion comprises a radius shaped curved.
 8. A corrugated box, comprising: a plurality of sidewalls arranged adjacent to each other and defining a seam there between, the sidewalls each comprising a seam edge and having a tab extending from the seam edge, the tab being arranged adjacent an inner or outer surface of the adjacent sidewall and being secured thereto.
 9. The corrugated box of claim 8, wherein the tabs from adjacent sidewalls interlock.
 10. The corrugated box of claim 8, wherein a first seam edge of a first sidewall includes an upper tab and a lower tab and a second seam edge of a second sidewall includes an upper tab and a lower tab.
 11. The corrugated box of claim 10, wherein the upper and lower tabs from the first sidewall are arranged adjacent an inner surface of the second sidewall.
 12. The corrugated box of claim 11, wherein the upper and lower tabs from the second sidewall are arranged adjacent an outer surface of the first sidewall.
 13. The corrugated box of claim 12, wherein the first seam edge includes a center tab and the center tab is arranged adjacent an outer surface of the second sidewall.
 14. The corrugated box of claim 12, wherein the second seam edge includes a center tab and the center tab is arranged adjacent an inner surface of the first sidewall.
 15. The corrugated box of claim 10, wherein the upper tab from the first sidewall is arranged adjacent an inner surface of the second sidewall and the lower tab from the first sidewall is arranged adjacent an outer surface of the second sidewall.
 16. The corrugated box of claim 15, wherein the upper tab from the second sidewall is arranged adjacent an outer surface of the first sidewall and the lower tab from the second sidewall is arranged adjacent an inner surface of the first sidewall.
 17. The corrugated box of claim 8, wherein the plurality of tabs are secured by sonic welding. 